Absorbent Articles Having a Breathable Stretch Laminate

ABSTRACT

An absorbent article may comprise a topsheet; a backsheet joined with the topsheet; an absorbent core between the topsheet and backsheet; and an elastic element comprising a breathable stretch laminate. The breathable stretch laminate may comprise a first substrate; and an elastic member joined to the first substrate, wherein said elastic member comprises a polyurethane. The breathable stretch laminate may exhibit a MVTR greater than about 300 grams per square meter per 24 hours and a force relaxation of less than about 50% after about 10 hours at 100° F. and 50% elongation.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of application Ser. No. 11/333,135,filed Jan. 17, 2006, the substance of which is incorporated herein byreference.

FIELD OF THE INVENTION

This invention is directed to absorbent articles such as diapers,training pants, adult incontinence articles, feminine hygiene articles,and the like comprising a breathable stretch laminate.

BACKGROUND OF THE INVENTION

It has long been known in the field of disposable absorbent articlesthat it is desirable to construct absorptive devices, such as disposablediapers with fasteners, pull-on diapers, training pants, sanitarynapkins, pantiliners, incontinence briefs, and the like, with stretchlaminates to improve the ease of motion and maintenance of a sustainedfit. Stretch laminates allow the disposable absorbent article toaccommodate a range of different sized wearers. A disposable absorbentarticle may have stretch laminates in a number of its structuresincluding the waist band, leg cuffs, side panels, elasticized topsheets,backsheet, ears, and fastening system.

Various vapor permeable, liquid impermeable polymeric films are known inthe art. For example, one method of making a polymeric film vaporpermeable, involves mixing a matrix polymer with a quantity (e.g.,10-70% by weight) of an organic or inorganic particulate filler such as,for example, calcium carbonate, and extruding a film from the blend. Thematrix polymer may include a polyolefin, such as polyethylene orpolypropylene, or various olefin copolymers. The film may be a monolayerfilm, a multilayer film which contains the polymer/filler matrix as aprimary layer along with thin breathable skin layers, or a multilayerfilm having more than one polymer/filler matrix layer. The film may bestretched. The particulate filler serves as nucleation sites causing theformation of voids in the film. However, films and laminates made fromthe films generally are not elastic. Even if an elastomer is used inlieu of the polyolefin, the relatively high concentration of particulatefiller often degrades the elastic character and tensile properties ofthe resulting film.

Another common method for making a polymeric vapor permeable filminvolves aperturing the film during the formation process. For example,needle-punching is a well known process for aperturing films. Aperturesmay also be formed by subjecting the film to fluid pressure such as awater jet or air jet. While these methods may be used to makeelastomeric films breathable, the resulting apertured elastomeric filmmay exhibit reduced tensile properties. In particular, apertured filmsoften have reduced tensile strengths compared to equivalentnon-apertured, monolithic films. In addition, apertured films are, ingeneral, more susceptible to tear and tear propagation while being heldat a constant strain when compared to non-apertured films.

Even when breathable elastomers and breathable stretch laminates areformed, these products may not exhibit mechanical characteristicsideally suited for use in disposable absorbent articles. One criticalcharacteristic for stretch laminates for use in disposable absorbentarticles such as disposable absorbent articles is that the stretchlaminate should exhibit a low force relaxation.

Stretch laminates (particularly for use in disposable absorbentarticles) ideally should exhibit high breathability with a minimalamount of force relaxation. Force relaxation quantifies an elastomer'sloss of force as a result of a constant strain and hold at apredetermined strain, temperature, and time. Many diaper componentscomprise a stretch laminate. The elastic character of the componentoften improves the fit and function of the diaper. For example,elasticized side panels are common on disposable absorbent articles suchas pant-type diapers. The elasticized side panels provide a snug,conforming fit that translates to improved containment of exudates.During wear, the elasticized side panels are maintained in an elongatedstate, and the elasticized side panel may exert an unload force. Overtime, the unload force may diminish. If the elasticized side panel losestoo much force, the diaper is prone to sagging which can result inincreased leakage.

Another factor to be considered in stretch laminate construction is thehysteresis properties of the elastomeric material. The elastomericmaterial should not exhibit unnecessarily large hysteresis area underthe curve since this evidences the presence of lower unload forces atlower strains (e.g., lower unload forces near strain exhibited in actualproduct use and application). Lower unload forces could indirectlyeffect the product fit. One approach to determine the improvedproperties of stretch laminate is by calculating the load (i.e., 200%strain) to unload (i.e., 50% return load strain). It is desirable toprovide a stretch laminate with a low load to unload ratio.

Accordingly, it would be desirable to provide a disposable absorbentarticle comprising a stretch laminate that exhibits a requisite degreeof breathability while maintaining a low degree of force relaxation. Thebreathable stretch laminate may exhibit a high degree of extensibilitywith a minimal degree of set. It would also be desirable to provide amethod for making such a disposable absorbent article. It is alsodesirable to provide a disposable absorbent article comprising abreathable stretch laminate that exhibits a requisite degree ofbreathability and requiring low load forces while maintaining a lowdegree of force relaxation.

SUMMARY OF THE INVENTION

The present invention relates to an absorbent article having a topsheet;a backsheet joined with the topsheet; an absorbent core between thetopsheet and backsheet; and an elastic element comprising a breathablestretch laminate. The breathable stretch laminate may comprise a firstsubstrate; and an elastic member joined to the first substrate, whereinsaid elastic member comprises a polyurethane. The breathable stretchlaminate may exhibit a MVTR greater than about 300 grams per squaremeter per 24 hours and a force relaxation of less than about 50% afterabout 10 hours at 100° F. and 50% elongation.

The present invention further relates to an absorbent article having atopsheet; a backsheet joined with the topsheet; an absorbent corebetween the topsheet and backsheet; and an elastic element comprising abreathable stretch laminate. The elastic element includes a breathablezero strain stretch laminate comprising an incrementally stretched firstnonwoven; and an elastic member joined to the incrementally stretchedfirst nonwoven. The elastic member comprises a phase-separating materialhaving at least a first phase with a first glass transition temperatureof less than −40° C. and a second phase with a second glass transitiontemperature of greater than 100° C., and wherein said phase-separatingmaterial comprises a polyurethane hard phase. The breathable zero strainstretch laminate exhibits a MVTR greater than about 300 grams per squaremeter per 24 hours, a force relaxation of less than about 50% afterabout 10 hours at 100° F. and 50% elongation, and a first cycle 200%load to 50% unload ratio of less than about 16.

The present invention further relates to methods by which to form thebreathable stretch laminate.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A-D are perspective views of embodiments of the breathablestretch laminate.

FIG. 1E is a schematic of a suitable process for forming the breathablestretch laminate.

FIG. 2 is a top plan view of a diaper containing the breathable stretchlaminate.

FIG. 3A is a top plan view of a pant containing the breathable stretchlaminate.

FIG. 3B is a perspective view of the pant, as shown in FIG. 3A,containing the breathable stretch laminate.

DETAILED DESCRIPTION OF THE PRESENT INVENTIONS

The absorbent articles of the present invention comprise a breathablestretch laminate. The breathable stretch laminate may be used within theabsorbent article wherever elastic properties are desired. Thebreathable stretch laminate generally comprises an elastic member joinedto a substrate. The elastic member may be a polyurethane. The breathablestretch laminate exhibits a Moisture Vapor Transmission Rate (MVTR) ofat least about 300 grams per square meter per 24 hours. In otherembodiments, the breathable stretch laminate exhibits a MVTR of at leastabout 700 grams per square meter per 24 hours or of at least about 1100grams per square meter per 24 hours. The breathable stretch laminateexhibits a force relaxation of less than about 50 percent after about 10hours at 100° F. and 50% elongation

I. DEFINITIONS

As used herein, the following terms shall have the meaning specifiedthereafter:

“Disposable,” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise discarded in an environmentallycompatible manner).

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on diapers, pant-typediapers (i.e., a diaper having a pre-formed waist opening and legopenings such as illustrated in U.S. Pat. No. 6,120,487), refastenablediapers or pant-type diapers, incontinence briefs and undergarments,diaper holders and liners, feminine hygiene garments such as pantyliners, absorbent inserts, and the like.

“Proximal” and “Distal” refer respectively to the location of an elementrelatively near to or far from the longitudinal or lateral centerline ofa structure (e.g., the proximal edge of a longitudinally extendingelement is located nearer to the longitudinal centerline than the distaledge of the same element is located relative to the same longitudinalcenterline).

“Body-facing” and “garment-facing” refer respectively to the relativelocation of an element or a surface of an element or group of elements.“Body-facing” implies the element or surface is nearer to the wearerduring wear than some other element or surface. “Garment-facing” impliesthe element or surface is more remote from the wearer during wear thansome other element or surface (i.e., element or surface is proximate tothe wearer's garments that may be worn over the disposable absorbentarticle).

“Longitudinal” refers to a direction running substantially perpendicularfrom a waist edge to an opposing waist edge of the article and generallyparallel to the maximum linear dimension of the article. Directionswithin 45 degrees of the longitudinal direction are considered to be“longitudinal”

“Lateral” refers to a direction running from a longitudinal edge to anopposing longitudinal edge of the article and generally at a right angleto the longitudinal direction. Directions within 45 degrees of thelateral direction are considered to be “lateral.”

“Disposed” refers to an element being located in a particular place orposition.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

“Film” refers to a sheet-like material wherein the length and width ofthe material far exceed the thickness of the material. Typically, filmshave a thickness of about 0.5 mm or less.

“Extendibility” and “extensible” mean that the width or length of thecomponent in a relaxed state can be extended or increased.

“Elastic,” “elastomer,” and “elastomeric” refer to a material whichgenerally is able to extend to a strain of at least 50% without breakingor rupturing, and is able to recover substantially to its originaldimensions after the deforming force has been removed.

“Elastomeric material” is a material exhibiting elastic properties.Elastomeric materials may include elastomeric films, scrims, nonwovens,and other sheet-like structures.

“Outboard” and “inboard” refer respectively to the location of anelement disposed relatively far from or near to the longitudinalcenterline of the diaper with respect to a second element. For example,if element A is outboard of element B, then element A is farther fromthe longitudinal centerline than is element B.

“Pant” refers to disposable absorbent articles having a pre-formed waistand leg openings. A pant may be donned by inserting a wearer's legs intothe leg openings and sliding the pant into position about the wearer'slower torso. Pants are also commonly referred to as “closed diapers”,“prefastened diapers”, “pull-on diapers”, “training pants” and“diaper-pants.”

“Stretch laminate” refers to an elastic member that is attached to atleast one substrate such as a polymeric film, a nonwoven, a woven, or ascrim. The elastic member may be attached to the material by any of anumber of bonding methods known to those skilled in the art, includingadhesive bonding, thermal bonding, pressure bonding, ultrasonic bonding,and the like. A stretch laminate is generally able to extend to a strainof at least 50% without breaking or rupturing, and is able to recoversubstantially to its original dimensions after the deforming force hasbeen removed.

“Substrate” refers to a sheet-like material. Suitable substrates includenonwoven webs, woven webs, knitted fabrics, films, film laminates,apertured films, nonwoven laminates, sponges, foams, scrims, and anycombinations thereof. Suitable substrates may comprise naturalmaterials, synthetic materials, or any combination thereof.

“Relaxed” or “relaxed state” means the state where no forces are appliedto a structure or element (other than naturally occurring forces such asgravity).

“Copolymer” refers to a polymer synthesized from two or more monomerswith different chemical structures.

“Breathable Monolithic Films” are non-porous, non-apertured films thatallow moisture vapor to be transmitted through the film via diffusion,absorption, and/or convection. Films that have a moisture vaportransmission rate of about 300 g/m²/24 hours or less are considerednon-breathable.

II. BREATHABLE STRETCH LAMINATE A. Structure

The breathable stretch laminate 10 (BSL) of the present inventioncomprises an elastic member 12 joined to a first substrate 14. Joiningof the elastic member 12 and the substrate 14 may be conducted by avariety of bonding methods such as heat bonds, pressure bonds,ultrasonic bonds, mechanical bonds, adhesive bonds, or any othersuitable attachment means or combinations of these attachment means asare known in the art. In certain embodiments, the elastic member 12 mayexhibit sufficient tack adhere to the substrate 14. In otherembodiments, the elastic member 12 may be applied to the substrate 14 ina molten or softened state such that the elastic member 12 fuses with orphysically interlocks the substrate 14. The dimensions of the breathablestretch laminate 10 are generally limited only by the end-use of thebreathable elastic laminate 10.

The elastic member 12 may comprise a variety of forms including, but arenot limited to films, bands, strands, individualized fibers, scrims,cross-hatch arrays, foams, or combinations thereof. In a certainembodiments, the elastic member 12 is a monolithic film. A monolithicfilm is a non-porous, non-apertured film that can be prepared viatypical film-forming methods such as solvent-casting or extrusion.Breathable monolithic films generally comprise a continuous hydrophilicmoiety for rapid diffusion of water vapor through the film.

FIGS. 1A-D depict several suitable embodiments of the breathable stretchlaminate 10. FIG. 1A depicts a breathable stretch laminate 10 having anelastic member 12 in the form of a monolithic film joined with asubstrate 14. The elastic member 12 and the substrate 14 are shown asbeing coterminous; however, either layer may have dimensions differingfrom the other layer. FIG. 1B depicts a BSL 10 having one or moreelastic members 12 joined with a substrate 14. The elastic members 12may take the form a strand, yarn, ribbon, or the like. FIG. 1C depicts aBSL 10 having one or more elastic members in the form of a cross-hatcharray joined with a substrate 14. A cross-hatch array may be formed inone instance by joining a plurality of elastic members 12 a in parallelto the substrate 14. A second plurality of elastic members 12 b may bejoined in parallel to the substrate 14. The second plurality 12 b may bejoined in a non-parallel configuration to the first plurality 12 a. Across-hatch array may also be formed by hot needle punching or otherperforation technique of an elastomeric film. A cross-hatch array mayalso be formed from a porous, macroscopically-expanded,three-dimensional elastomeric web as described in U.S. PatentApplication Publication No. 2004/0013852. The publication describes howthe cross-hatch array can be achieved by forming the film on a porousforming structure and applying a fluid pressure differential across thethickness of the film. The fluid pressure differential causes the filmto conform to the supporting structure and rupture thereby creating across-hatch array.

FIG. 1D depicts a breathable stretch laminate 10 having one or moreelastic members 12 (FIG. 1D depicts the elastic member 12 as a film)joined to two or more substrates: first substrate 14 a and secondsubstrate 14 b. The particular order of the breathable stretch 10 layerscan vary; however, in the embodiment depicted, the elastic members 12are disposed between the first substrate 14 a and the second substrate14 b, and may be bonded to one or both. The first and second substrate14 a, 14 b may comprise the same or different material.

B. Method of Making

The techniques for the formation of stretch laminates are well known inthe art, and these techniques may be applicable in the formation of theBSL 10 of the present invention. One technique for creating a stretchlaminate, which is commonly known as “stretch bonding,” involves atleast one elastic member 12 being joined to a substrate 14 while theelastic member 12 is in an elongated. The elastic member 12 may be inany well known form such as a strand, band, ribbon, film, scrim, or thelike. Generally, the elastic member may be elongated to at least 25% ofits relaxed length. An adhesive may be used to improve the attachmentbetween the elastic member 12 and the substrate 14. After joining, theelastic member 12 is allowed to recovery thereby gathering the substrateand creating a stretch laminate.

Another technique for creating a stretch laminate, which is commonlyknown as “neck bonding,” involves an elastic member 12 being bonded to asubstrate 14 while the substrate is extended and necked. The resultinglaminate is stretchable and generally exhibits elastic character in adirection generally parallel to the direction of necking of thesubstrate 14. In certain embodiments, the substrate 14 may be anon-elastic substrate. Examples of neck-bonded laminates are describedin U.S. Pat. Nos. 5,226,992; 4,981,747; 4,965,122; and 5,336,545. Avariant of “neck bonding” involves bonding an elongated elastic member12 to a necked substrate 14. An adhesive may be used to improve theattachment between the elastic members and the substrate. Examples ofsuch bonded laminates are described in U.S. Pat. Nos. 5,114,781 and5,116,662.

In another technique for forming a stretch laminate, elastic members canbe attached to a substrate in either a relaxed configuration orpartially stretched configuration. An adhesive may be used to improvethe attachment between the elastic members and the substrate. Theresulting laminate can be made stretchable (or more stretchable in thecase of partially stretched strands or film) by subjecting the laminateto an elongation process which elongates the substrate permanently, butelongates the elastic members only temporarily. Such processes are knownin the art as “zero strain” stretch laminate formation. In certainembodiments, a zero strain stretch laminate may be subjected toincremental stretching. Incremental stretching may be performed by apair of meshing corrugated rolls. The corrugated rolls support thelaminate during the stretching operation at a plurality of closelyspaced locations which correspond to the width of the corrugations. Thisresults in a substantially uniform incremental stretching of eachunsupported segment of the laminate between adjacent support pointsrather than highly localized stretching as often occurs when only theoutermost extremities of the web are subjected to tension (e.g.,laminate subjected to tensioning rolls or off-speed rolls). A suitablezero strain incremental stretching process is described in U.S. Pat.Nos. 5,167,897, 5,156,793, and 6,843,134.

An alternate technique for the formation of a stretch laminate isdisclosed in U.S. Patent Application Publication Nos. 2003/0088228A1,2003/0091807A1, and 2004/0222553A1. The technique disclosed in thesepublications involves forming the elastic member by hot melt applicationof one or more elastomeric compositions onto a substrate to form one ormore elastic members followed by the incremental stretching of thesubstrate so as to confer the stretch properties of the elastomer to thesubstrate. In certain embodiments, the elastic member may be formed byhot melt application of one or more thermoplastic elastomers onto anincrementally stretched substrate. Suitable application methods include,for example, direct gravure, offset gravure, and flexographic printing.Each of these methods allows deposition of an amount of elastomer in anyshape and direction, thus providing substantial flexibility in thestretch character exhibited by the stretch laminate. Other conventionalmethods for stretch laminate formation are within the scope of thisdescription.

In an alternate embodiment, the breathable stretch laminate 10 may beformed by an integrated process. The process may involve the elasticmember 12 being formed contemporaneously with the formation of thelaminate 10. In other words, the elastic member 12 may be formed as onestep in the uninterrupted process of making the laminate 10. In onesuitable process as shown in FIG. 1E, a cooling drum 132 is provided.The cooling drum 132 rotates about an axis and may have a cooled outersurface. An extruder 130 is provided that extrudes a molten or softenedelastomeric composition 138 onto the cooled outer surface of the coolingdrum to form one or more elastic members 12. A first roller 134 and asecond roller 136 rotating about parallel axes may be provided. Thefirst and second rollers 134, 136 may form a nip 135 there between. Thesubstrate 14 may be provided and may be conveyed to the second roller136. The elastic members 12 may be conveyed from the cooling drum 132 tothe first roller 134. Generally, the distance between the cooling drum132 and the first roller 134 should be minimized to improve the handlingefficiency of the elastic members 12. The elastic members 12 andsubstrate 14 are passed through the nip 135 thereby joining theplurality of elastic members 12 to the substrate 14. An adhesive may beused to improve the attachment between the elastic members 12 and thesubstrate 14. Additional substrates may be joined to the breathablestretch laminate 10. The resulting laminate may be subjected to furtherprocessing such as incremental stretching by way of corrugated rolls.

Furthermore, the surface speed of the first roller 134 may be greaterthan the surface speed of the cooling drum 132. In such a case, theelastic members 12 may be elongated prior to attachment to the substrate14.

C. Elastic Member

The elastic member 12 may comprise a polyurethane, optionally at leastone modifying resin, and optionally one or more additives. As usedherein, polyurethane includes polymers having a urethane and/or urealinkage. The polyurethanes useful herein are preferably selected from:polyurethane (co)polyethers, polyurethane (co)polyesters,polyurethane/urea (co)polyethers, or polyurethane/urea (co)polyesters,Preferred are polyurethane-co-poly(ethylene glycol),polyurethane-co-poly(tetramethylene glycol), andpolyurethane-co-poly(propylene glycol) and mixtures thereof.

The basis weight of the elastic member 12 may be varied. In certainembodiments, the elastic member 12 may have a basis weight of less thanabout 100 g/m² (e.g., use of the BSL 10 the front or back ear of a pantas discussed below in reference to FIGS. 3A-B). In certain embodiments,the elastic member 12 may have a basis weight of less than about 35 g/m²(e.g., use of the BSL 10 in the front or back ear of a diaper asdiscussed below in reference to FIG. 2). In certain embodiments, theelastic member 12 may have a basis weight of less than about 10 g/m²(e.g., use of the BSL 10 in an elastic backsheet).

The polyurethanes may be component of a phase separating material havingat least one hard phase (also referred to as a hard block or hardsegment) and at least one soft phase (also referred to as a soft blockor soft segment). Each phase may exhibit a distinct glass transition,temperatures. The soft phase generally exhibits a sufficiently low glasstransition (Tg) temperature and/or melting temperature so as not to formglassy or crystalline regions at the use temperature of the copolymer.In one embodiment, the use temperature may be between about roomtemperature (about 22° C.) and about body temperature (about 37° C.).However, other use temperatures are envisioned and within the scope ofthis invention. Such soft phases may exhibit a Tg of less than about−40° C. The soft phase may exhibit a Tg of less than about −65° C. orabout −75° C. The hard phase may have a Tg greater than about 65° C. Thehard phase may exhibit a Tg of greater than about 135° C.

Glass transition temperatures referred to herein are determined byDifferential Scanning Calorimetry (DCS) using a temperature ramp rate of20° C./min. The calorimeter should be capable of heating/cooling ratesof at least 20° C./min over a temperature range, which includes theexpected Tg's of the sample that is to be tested, e.g. of from −90° to250° C., and the calorimeter should have a sensitivity of about 0.2 μW.The Q1000 DSC available from TA Instruments of New Castle, Del. iswell-suited to determining the Tg's referred to herein. The material ofinterest can be analyzed using a temperature program such as:equilibrate at −90° C., ramp at 20° C./min to 120° C., hold isothermalfor 5 minutes, ramp 20° C./min to −90° C., hold isothermal for 5minutes, ramp 20° C./min to 250° C. The data (heat flow versustemperature) from the second heat cycle is used to calculate the Tg viaa standard half extrapolated heat capacity temperature algorithm.Typically, 3-5 g of a sample material is weighed (±0.1 g) into analuminum DSC pan with crimped lid.

The hard phase may comprise a polyurethane block meeting the requisiteglass transition temperature requirements. The soft phase may compriseone or more polyethers. Suitable polyethers include polyethylene glycol,polytetramethylene glycol, polypropylene glycol, and mixture thereof.Polyethylene glycol soft blocks are useful since polyurethanes blockcopolymers with polyethylene glycol blocks are more breathable thanthose containing polytetramethylene glycol or polypropylene glycol.Although polyethylene glycol blocks provide ideal breathability, amixture of polyethylene glycol blocks with other polyethers (e.g.,polytetramethylene glycol) blocks is particularly suited to givemechanical properties suitable for use in stretch laminates. The softphase polyethers may be provided by polymerization of the hard phasecomponent with a macrodiol. Macrodiols may have a base structure ofHO—(—R—O—)_(n)—H where R is a repeat unit such as ethylene, butane,hexane, etc. and where n is greater than 1. By way of example, suitablemacrodiols include polymers of ethylene glycol, butane diol, hexanediol, dipropylene diol, cyclohexylenediol, and combinations.Furthermore, the soft phase may be provided by polymerization of thehard phase component with suitable hydroquinoines including ethoxylatedhydroquinone. The phase separating material optionally may be graftedand/or be partially modified with chemical substituents (e.g., hydroxylgroups or carboxylates) to tailor the Tg of the soft block, to affectsurface characteristics, or to increase breathability.

In certain embodiments, polyurethane may have a weight average molecularweight of at least 40 kDa. In certain embodiments, the molecular weightof the soft phase may be at least 500 Da, at least 1000 Da, or even atleast 2000 Da.

The polyurethane may be derived from a polymerisation reaction of adiisocyanate with a diol, such as, for example, butane diol, orcyclohexane diol. Alternately, the polyurethane may be derived from apolymerisation reaction of an aromatic diisocyanate and an aliphaticdiol such as ethylene glycol, butane diol, propane diol, or mixturesthereof. A suitable diisocyanate used to form the polyurethane or thepolyurethane segments of the block copolymer is methylene bis(phenylisocyanate).

The polyurethane may contain a polyether intermediate derived fromtetrahydrofuran monomers so that tetramethylene oxide repeat units arepresent in the intermediate which also has terminal hydroxyl groups.Optionally, selective types of other alkylene oxide monomers such aspropylene oxide, ethylene oxide or a mixture of propylene oxide withethylene oxide can be utilized to produce the polyurethane.

A suitable phase separating material may be polymerized from thestarting monomers of (i) a polyether intermediate having at least atetramethylene oxide repeat unit and, optionally, a repeat unit derivedfrom propylene oxide and/or ethylene oxide; (ii) a diisocyannate; and(iii) a diol or ethoxylated hydroquinone. Suitable diols includeethylene glycol, butane diol, hexane diol, dipropylene diol,cyclolhexylenediol, and combinations.

The elastic member 12 may comprise one or more plasticizers. Suitableplasticizers may associate or phase mix elastomeric polymer to reducehardness without effecting properties. The elastic member 12 maycomprise plasticizers in amounts from about 0% to about 60%. Suitableplasticizers include benzyl phthalate, benzyl butyl phthalate, andpoly(ethylene glycol) such as PEG-400.

The elastic member 12 may comprise a variety of additives. Suitableadditives include, for example, stabilizers, antiblocking agents,viscosity modifiers, processing aids, slip agents antioxidants,opacifying pigments, colorants, mineral fillers, UV absorbers andbacteriostats may be employed to prevent thermal, oxidative, andbio-chemical degradation of the elastic member 12. Generally, additivesmay account for about 0.01% to about 60% of the total weight of theelastic member 12. In other embodiments, the composition comprises fromabout 0.01% to about 25%. In other suitable embodiments, the compositioncomprises from about 0.01% to about 10% by weight, of additives.

Various colorants and fillers are known in the art and may be includedas additives within the composition that forms the elastic member 12.Colorants can include dyes and pigments such as titanium dioxide.Fillers may include such materials as talc and clay. Other additives mayinclude dyes, UV absorbers, odor control agents, perfumes, fillers,desiccants, and the like.

D. Substrates

Suitable substrates 14 for use include nonwoven webs, woven webs,knitted fabrics, films, film laminates, apertured films, nonwovenlaminates, sponges, foams, scrims, and any combinations thereof.Suitable substrates may comprise natural materials, synthetic materials,or any combination thereof. For use in absorbent articles andparticularly in diapers and like products, the substrate 14 is generallycompliant, soft-feeling, and non-irritating to a wearer's skin. Incertain embodiments, substrates 14 may include nonwoven webs such asspunbond webs, meltblown webs, carded webs, and combinations thereof(e.g., spunbond-meltblown composites and variants).

E. Characteristics of the Breathable Stretch Laminate

The BSL 10 of the present invention exhibits unique physicalcharacteristics. In certain embodiments, it is important for the BSL 10to exhibit a requisite degree of breathability as determined by theMoisture Vapor Transmission Rate (MVTR) test described below. The BSL 10may exhibit a MVTR of at least about 300 g/m²/24 hours. In alternateembodiments, the BSL 10 may exhibit a MVTR of at least about 500, 750,or 1000 g/m²/24 hours.

The BSL 10 may exhibit a force relaxation of less than about 50% asdetermined by the Sustained Force Relaxation Test described below. Inalternate embodiments, the BSL 10 may exhibit a force relaxation of lessthan about 40%, 30%, or 25%. Furthermore, the BSL 10 may exhibit a 200%load to 50% unload ratio, as measured in the first cycle according tothe 200% 2 Cycle Hysteresis Method described below, of less than about16. In other embodiments, the 200% load to 50% unload ratio is less thanabout 13. A smaller value for the load-to-unload ratio correlates to asmaller hysteresis area under the curve which evidences the presence ofhigher unload forces at lower strains (i.e., the unload forces moreclosely approximate the load forces).

III. ABSORBENT ARTICLE

The BSL 10 may be utilized in a variety of consumer and commercialproducts. However, the BSL 10 has particular benefit within absorbentarticles, particularly disposable absorbent articles such as diapers andthe like. The BSL 10 may be used in a variety of regions or in a varietyof elements to provide elastic character to the absorbent article.

FIG. 2 is a plan view of an exemplary, non-limiting embodiment of adiaper 20 in a flat, uncontracted state (i.e., without elastic inducedcontraction). The garment-facing surface 120 of the diaper 20 is facingthe viewer and the body-facing surface 122 is opposite the viewer. Thediaper 20 includes a longitudinal centerline 100 and a lateralcenterline 110. The diaper 20 may comprise a chassis 22. In certainembodiments, the chassis 22 comprises the main structure of the diaper20 and other features may be added to form the composite diaperstructure. The diaper 20 and chassis 22 are shown to have a front waistregion 36, a back waist region 38 opposed to the front waist region 36,and a crotch region 37 located between the front waist region 36 and theback waist region 38. The waist regions 36 and 38 generally comprisethose portions of the diaper 20 which, when worn, encircle the waist ofthe wearer. The waist regions 36 and 38 may include elastic elementssuch that they gather about the waist of the wearer to provide improvedfit and containment. The crotch region 37 is that portion of the diaper20 which, when the diaper 20 is worn, is generally positioned betweenthe legs of the wearer.

The outer periphery of diaper 20 and/or chassis 22 is defined bylongitudinal edges 12 and lateral edges 14. The chassis 22 may haveopposing longitudinal edges 12 that are oriented generally parallel tothe longitudinal centerline 100. However, for better fit, longitudinaledges 12 may be curved or angled to produce, for example, an “hourglass”shape diaper when viewed in a plan view. The chassis 22 may haveopposing lateral edges 14 that are oriented generally parallel to thelateral centerline 110.

The chassis 22 may comprises a topsheet 24 having longitudinal edges 25,a backsheet 26, and an absorbent core 28 between the topsheet 24 and thebacksheet 26. The absorbent core 28 may have a body-facing surface and agarment facing-surface. The topsheet 24 may be joined to the core 28and/or the backsheet 26. The backsheet 26 may be joined to the core 28and/or the topsheet 24. It should be recognized that other structures,elements, or substrates may be positioned between the core 28 and thetopsheet 24 and/or backsheet 26. The topsheet 24, the backsheet 26, andthe absorbent core 28 may be assembled in a variety of well-knownconfigurations as described generally in U.S. Pat. Nos. 3,860,003;5,151,092; 5,221,274; 5,554,145; 5,569,234; 5,580,411; and 6,004,306.

The absorbent core 28 may comprise a wide variety of otherliquid-absorbent materials commonly used in disposable diapers and otherabsorbent articles. Examples of suitable absorbent materials includecomminuted wood pulp, which is generally referred to as air felt;chemically stiffened, modified or cross-linked cellulosic fibers;superabsorbent polymers or absorbent gelling materials; melt blownpolymers, including co-form, biosoluble vitreous microfibers; tissue,including tissue wraps and tissue laminates; absorbent foams; absorbentsponges; and any other known absorbent material or combinations ofmaterials. Exemplary absorbent structures for use as the absorbent core28 are described in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735;4,888,231; 5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207;5,397,316; 5,625,222; and 6,932,800. Further exemplary absorbentstructures may include non-removable absorbent core components andremovable absorbent core components. Such structures are described inU.S. Publication 2004/0039361A1; 2004/0024379A1; 2004/0030314A1;2003/0199844A1; and 2005/0228356A1.

The absorbent core 28 may comprise a fluid acquisition component, afluid distribution component, and a fluid storage component. A suitableabsorbent core 28 comprising an acquisition layer, a distribution layer,and a storage layer is described in U.S. Pat. No. 6,590,136.

Another suitable absorbent core construction is described in U.S.Publication No. 2004/0167486 to Busam et al. The absorbent core of theaforementioned publication uses no or, in the alternative, minimalamounts of absorbent fibrous material within the core. Generally, theabsorbent core may include no more than about 20% weight percent ofabsorbent fibrous material (i.e., [weight of fibrous material/totalweight of the absorbent core]×100).

The topsheet 24 is generally a portion of the diaper 20 that may bepositioned at least in partial contact or close proximity to a wearer.Suitable topsheets 24 may be manufactured from a wide range of materialssuch as woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers; apertured plastic films;porous foams or reticulated foams. The topsheet 24 is generally supple,soft feeling, and non-irritating to a wearer's skin. Generally, at leasta portion of the topsheet 24 is liquid pervious, permitting liquid toreadily penetrate through the thickness of the topsheet 24. Suitably,the topsheet 24 comprises a polymer (e.g. polyethylene) derived from arenewable resource. Alternatively, a suitable topsheet 24 is availablefrom BBA Fiberweb, Brentwood, Tenn. as supplier code 055SLPV09U. Thetopsheet 24 may be fully or partially elasticized or may beforeshortened so as to provide a void space between the topsheet 24 andthe core 28. Exemplary structures including elasticized or foreshortenedtopsheets are described in more detail in U.S. Pat. Nos. 4,892,536;4,990,147; 5,037,416; and 5,269,775.

Any portion of the topsheet 24 may be coated with a lotion as is knownin the art. Examples of suitable lotions include those described in U.S.Pat. Nos. 5,607,760; 5,609,587; 5,635,191; and 5,643,588. The topsheet24 may be fully or partially elasticized or may be foreshortened so asto provide a void space between the topsheet 24 and the core 28.Exemplary structures including elasticized or foreshortened topsheetsare described in more detail in U.S. Pat. Nos. 4,892,536; 4,990,147;5,037,416; and 5,269,775.

The backsheet 26 is generally positioned such that it may be at least aportion of the garment-facing surface 120 of the diaper 20. Backsheet 26may be designed to prevent the exudates absorbed by and contained withinthe diaper 20 from soiling articles that may contact the diaper 20, suchas bed sheets and undergarments. In certain embodiments, the backsheet26 is substantially water-impermeable; however, the backsheet 26 may bemade breathable so as to permit vapors to escape while preventing liquidexudates from escaping. The polyethylene film may be made breathable byinclusion of inorganic particulate material and subsequent tensioning ofthe film. Breathable backsheets may include materials such as wovenwebs, nonwoven webs, composite materials such as film-coated nonwovenwebs, and microporous films. Suitably, the backsheet 26 comprises apolymer such (e.g. polyethylene) derived from a renewable resource asdisclosed above. Alternative backsheets 26 derived from non-renewableresources include films manufactured by Tredegar Industries Inc. ofTerre Haute, Ind. and sold under the trade names X15306, X10962, andX10964; and microporous films such as manufactured by Mitsui Toatsu Co.,of Japan under the designation ESPOIR NO and by EXXON Chemical Co., ofBay City, Tex., under the designation EXXAIRE. Other alternativebreathable backsheets 26 are described in U.S. Pat. Nos. 5,865,823,5,571,096, and 6,107,537.

Backsheet 26 may also consist of more than one layer. For example, thebacksheet 26 may comprise an outer cover and an inner layer. The outercover may have longitudinal edges and the inner layer may havelongitudinal edges. The outer cover may be made of a soft, non-wovenmaterial. The inner layer may be made of a substantiallywater-impermeable film. The outer cover and an inner layer may be joinedtogether by adhesive or any other suitable material or method. Suitably,the nonwoven outer cover and the water-impermeable film comprisepolymers (e.g., polyethylene) derived from. renewable resources.Alternatively, a suitable outer cover and inner layer derived fromnon-renewable resources are available, respectively, as supplier codeA18AH0 from Corovin GmbH, Peine, Germany and as supplier code PGBR4WPRfrom RKW Gronau GmbH, Gronau, Germany. While a variety of backsheetconfigurations are contemplated herein, it would be obvious to thoseskilled in the art that various other changes and modifications can bemade without departing from the spirit and scope of the invention.

The breathable stretch laminate 10 of the present invention may bejoined to the backsheet 26, topsheet 24, or absorbent core 28 or formedfrom one or more components that form the backsheet 26, topsheet 24, orabsorbent core 28. Furthermore, the backsheet 26, topsheet 24, orabsorbent core 28 may comprise the breathable stretch laminate 10. Forexample, the backsheet 26 may comprise the breathable stretch laminate10 thereby forming an elastic backsheet 26. The breathable stretchlaminate 10 may be disposed in any location where elastic character isdesired.

The diaper 20 may include back ears 42 (shown in FIG. 2), front ears 40,or both (shown in FIG. 3). The front and/or back ears 42 may be unitaryelements of the diaper 20 (i.e., they are not separately manipulativeelements secured to the diaper 20, but rather are formed from and areextensions of one or more of the various layers of the diaper). Incertain embodiments, the ears 40, 42 may be discrete elements that arejoined to the chassis 22, as shown in FIG. 2. Discrete ears 40, 42 maybe joined to the chassis 22 by any bonding method known in the art suchas adhesive bonding, pressure bonding, heat bonding, and the like. Inother embodiments, the ears 40, 42 may comprise a discrete elementjoined to the chassis 22 with the chassis 22 having a layer, element, orsubstrate that extends over the ear 40, 42. The ears 40, 42 may beextensible, inextensible, elastic, or inelastic. The ears 40, 42 may beformed from nonwoven webs, woven webs, knitted fabrics, polymeric andelastomeric films, apertured films, sponges, foams, scrims, andcombinations and laminates thereof. In certain embodiments the frontears and back ears 42 may be formed of the breathable stretch laminate10 of the present invention.

The diaper 20 may further include leg cuffs 32 a, 32 b which provideimproved containment of liquids and other body exudates. Leg cuffs 32 a,32 b may also be referred to as gasketing cuffs, outer leg cuffs, legbands, side flaps, elastic cuffs, barrier cuffs, second cuffs, inner legcuffs, or “stand-up” elasticized flaps. U.S. Pat. No. 3,860,003describes a disposable diaper which provides a contractible leg openinghaving a side flap and one or more elastic members to provide anelasticized leg cuff (i.e., a gasketing cuff). U.S. Pat. Nos. 4,808,178and 4,909,803 describe disposable diapers having “stand-up” elasticizedflaps (i.e., barrier cuffs) which improve the containment of the legregions. U.S. Pat. Nos. 4,695,278 and 4,795,454 describe disposablediapers having dual cuffs, including gasketing cuffs and barrier cuffs.

FIG. 2 shows the diaper 20 having dual cuffs, gasketing cuff 32 a andbarrier cuff 32 b. The barrier cuff 32 b may include one or more barrierelastic members 33 b. The barrier elastic members 33 b may be joined toa barrier cuff substrate 34. In certain embodiments, the barrier cuffsubstrate 34 may be a polymeric film or nonwoven. The barrier cuff 32 bmay be disposed on the body-facing surface of the chassis 22. Thebarrier cuff 32 b may comprise the breathable stretch laminate 10 of thepresent invention wherein the elastic member 12 and substrate 14 of theBSL 10 correspond to the barrier elastic members 33 b and barrier cuffsubstrate 34 of the barrier cuff 32 b. The barrier cuff substrate 34 mayextend laterally from the longitudinal edge 12 of the chassis 22 to apoint inboard of the longitudinal edge 122. The barrier cuff 32 bgenerally extends longitudinally at least through the crotch region 37.

The gasketing cuff 32 a may include one or more gasketing elasticmembers 33 a. The gasketing elastic member 33 a may be joined to one ormore of the existing elements or substrates of the diaper 20 (e.g.,topsheet 24, backsheet 26, barrier cuff substrate 34, etc.). Thegasketing cuff 32 a may comprise the breathable stretch laminate 10 ofthe present invention wherein the elastic member 12 and substrate 14 ofthe BSL 10 correspond to the gasketing elastic members 33 a and any oneor more of the existing elements or substrates of the diaper 20.

The diaper 20 may also comprise an elastic waist feature 60. The elasticwaist feature 60 is generally intended to elastically expand andcontract to dynamically fit the wearer's waist. The waist feature 60 mayenable the diaper 20 to provide improved fit and containment. The diapermay have two elastic waist features 60, one disposed in the front waistregion 36 and one disposed in the back waist region 38. The elasticwaist feature 60 may be a discrete element joined to the diaper 20 orthe elastic waist feature 60 may be integral to the diaper 60 (i.e., theelastic waist feature 60 is not a separate element but is a region ofthe diaper 20 exhibiting elasticity). The waist elastic 62 generallywill allow for lateral elongation and recovery. In other embodiment, theelastic waist feature 60 may comprise the breathable stretch laminate 10of the present invention.

The diaper 20 may also include a fastening system 50. When fastened, thefastening system 50 interconnects the front waist region 36 and the backwaist region 38 resulting in a waist circumference that may encircle thewearer during wear of the diaper 20. The fastening system 50 may includean engaging member 52 and a receiving member 54. The engaging member 52may have an engaging surface 53 that covers a portion or the entireengaging member 52. The engaging surface 53 may comprise hooks, loops,an adhesive, a cohesive, a button, or other fastening element. Thereceiving member 54 may comprise a receiving surface 55 acceptsengagement of the engaging member 52. The receiving surface 55 may covera portion of the entire receiving member 54. The receiving surface 55 isconstructed to mate with or engage with the engaging surface 53 of theengaging member 52. For example, a receiving surface 55 of looped ornonwoven may be paired with an engaging surface 53 of hooks. Thefastening system 50 may comprises a fastener such as tape tabs, hook andloop fastening components, interlocking fasteners such as tabs & slots,buckles, buttons, snaps, and/or fastening components, although any otherknown fastening means are generally acceptable. Exemplary surfacefastening systems are disclosed in U.S. Pat. Nos. 3,848,594; 4,662,875;4,846,815; 4,894,060; 4,946,527; 5,151,092; and 5,221,274. An exemplaryinterlocking fastening system is disclosed in U.S. Pat. No. 6,432,098.The fastening system 50 may also provide a means for holding the articlein a disposal configuration as disclosed in U.S. Pat. No. 4,963,140. Thefastening system 50 may also include primary and secondary fasteningsystems, as disclosed in U.S. Pat. No. 4,699,622. The fastening system50 may be constructed to reduce shifting of overlapped portions or toimprove fit as disclosed in U.S. Pat. Nos. 5,242,436; 5,499,978;5,507,736; and 5,591,152.

In alternative embodiments, the diaper may be pre-formed by themanufacturer to create a pant. The pant may be pre-formed such that thefirst waist region 36 is joined to the back waist region 38 therebyforming a waist opening back waist region 38 by a refastenable mechanismsuch as fastening system or may be joined by a refastenable and/or anon-refastenable bond (e.g., seam, weld, adhesive, cohesive bond,fastener, etc.). A suitable refastenable bond may be provided with theuse of a fastening system 50. A non-refastenable bond may be formed bycommon bonding techniques including adhesive bonding, a pressurebonding, a heat bonding, ultrasonic bonding, and the like.

An exemplary pant 320 is shown in FIGS. 3A-B. FIG. 3A shows the pant 320in a planar unseamed state with the garment-facing surface 120 facingthe viewer. FIG. 3B shows the pant 320 of FIG. 3A in a seamed state andfrom a perspective view. Unless noted otherwise, the callouts of inFIGS. 3A-B refer to the same elements as the diaper 20 of FIG. 2. Thepant 320 shown without a fastening system. The front ear 40 and back ear42 are joined at a seam 49 by multiple bonds. The pant 320 is also shownhaving a waist feature 60 in both, the front waist region 36 and theback waist region 38. Other suitable pants are disclosed in U.S. Pat.Nos. 5,246,433; 5,569,234; 6,120,487; 6,120,489; 4,940,464; 5,092,861;5,897,545; 5,957,908; and U.S. patent application Ser. No. 10/171,249.

Test Methods

Sustained Load Force Relaxation Sample laminates are cut using a 1″×2″die. The weight and the thickness of the laminates are recorded as wellas the process direction (MD or CD). Polyester backed high temperaturetape (available from McMaster-Carr Catalogue item #7630A42) is appliedto the top and bottom 0.5 inches of the cut laminate, leaving a 1 inchgage length. The sample is placed into vertically aligned GF-1 ViseAction Tensile Grips available from Chatillon Force Measurement Systems,Largo, Fla., which are within a test chamber (described below) set at100° F. Once the temperature has equilibrated to 100° F., the dataacquisition software is engaged and the sample is manually strained to50% engineering strain (1.5 inch grip separation). Force (N) is recordedfor 10 hours (the sampling rate is decreased as time progresses duringthe test to minimize the data file size). The force relaxation at agiven time, t, is calculated according to [(initial force-force at timet)/initial force].

Sustained Load Force Relaxation Test Chamber: The test chamber consistsof a 25×11×16 inch (height×width×depth) enclosure surrounding a tubularstand which supports a pair of vertically aligned manually actuatedgrips. The top grip is fixed to a force transducer, Interface ModelSMT1-1.1 available from Interface, Inc., Scottsdale, Ariz. The bottomgrip is attached to a manually actuated screw which allows for the gripto raised and lowered. The zero position for the grips provides for a1.0 inch gap between said grips. An electronic positioning device,ProScale Model 150 available from Accurate Technology, Inc., ofFletcher, N.C., is attached to the bottom grip to monitor the distancebetween the grips. The temperature within the test chamber is maintainedusing an electronic controller (West 6100+, available from ISE, Inc.,Cleveland, Ohio), resistance heater, and thermocouple positioned nearthe test sample. The output signal from the force transducer isprocessed using Interface Model SGA Strain Gage Transducer Amplifieravailable from Interface, Inc. Scottsdale, Ariz. and captured on a DellLatitude (available from Dell Inc., Round Rock, Tex.) computer usingMeasurement Computing Corporation (Middleboro, Mass.) PC card DAS16/16.The data acquisition software, developed in-house, logs time and load atprogrammed time intervals.

200% 2 Cycle Hysteresis Method A uniaxial strain is applied to a flatsample and measuring the force that is required to elongate the sample.The film samples are herein strained in the cross-direction, whenapplicable. Sample laminates are cut using a 25×50 mm (width×length)die. The 25×50 mm sample is placed into the pneumatic grips of a MTSSynergie 200 materials tester available from MTS Corporation, Cary,N.C., with a 1.0 inch grip separation between (zero position) the gripswhich are available as Advantage Pneumatic Grips Model 200N from MTSCorporation, Cary, N.C. The grips are vertically aligned with the bottomgrip fixed to the frame and the top grip attached to the forcetransducer, MTS model #100-090-197 available from MTS Corporation, Cary,N.C., which is attached to the machine crosshead. The full scalecapacity of the load cell must exceed the greatest resistance load fromthe test film during the test. The test consists of two move segments.The first move segment consists of the crosshead extending the film to200% engineering strain (3 inch grip separation) at 250 mm/minute andholding the sample at 200% strain for 30 seconds and then returning thecrosshead to the zero position at 250 mm/min. The sample is held at thezero position for 60 seconds. The second move segment is a repetition ofthe first. The first move segment is identified as cycle 1, while thesecond move segment is identified as cycle 2. The method reports Load at200% (peak load at 200% engineering strain), Unload at 50% (load at 50%engineering strain during return movement to zero), and Unload at 30%(load at 50% engineering strain during return movement to zero).

Moisture Vapor Transmission Rate (MVTR) Method The MVTR method measuresthe amount of water vapor that is transmitted through a sample underspecific temperature and humidity. The transmitted vapor is absorbed byCaCl₂ desiccant and determined gravimetrically. Samples are evaluated intriplicate, along with a reference film sample of establishedpermeability (e.g., Exxon Exxaire microporous material #XBF-110W) thatis used as a positive control.

The test uses a flanged cup (machined from Delrin (McMaster-Carr Catalog#8572K34) and anhydrous CaCl₂ (Wako Pure Chemical Industries, Richmond,Va.; Catalog #030-00525). The height of the cup is 55 mm with an innerdiameter of 30 mm and an outer diameter of 45 mm. The inner volume ofthe cup is approximately 38.8 cm³. The cup is fitted with a siliconegasket and lid containing 3 holes for thumb screws to completely sealthe cup. Desiccant particles used are sized to pass through a No. 8sieve but not through a No. 10 sieve. Samples are resized toapproximately 1.5″×2.5″ and are substantially free of visible defectssuch as air bubbles, holes, inclusions, and cuts. Samples are to havesharp and visibly defect-free edges. If the sample is defective, it isto be discarded and replaced. The sample must completely cover the cupopening having a circular area 0.0007065 m².

The cup is filled with CaCl₂ to within about 1 cm of the top. The cup istapped on the counter 10 times, and the CaCl₂ surface is leveled. Theamount of CaCl₂ is adjusted until the headspace between the film surfaceand the top of the CaCl₂ is 1.0 cm. The film is placed on top of the cupacross the opening (30 mm) and is secured using the silicone gasket,retaining ring, and thumb screws. Properly installed, the specimenshould not be wrinkled or stretched. The sample assembly is weighed withan analytical balance and recorded to ±0.001 g. The assembly is placedin a constant temperature (40±3° C.) and humidity (75±3% RH) chamber for5.0 hr±5 min. The sample assembly is removed, covered with Saran Wrap®and is secured with a rubber band. The sample is equilibrated to roomtemperature for 30 min, the plastic wrap and rubber band are removed,and the assembly is reweighed and the weight is recorded to ±0.001 g.The absorbed moisture M_(a) is the difference in initial and finalassembly weights. MVTR, in g/m²/24 hr (g/m²/day), is calculated as:

MVTR=M _(a)/(A*0.208 day)

Replicate results are averaged and rounded to the nearest 100 g/m²/24 hr(e.g., 2865 g/m²/24 hr is herein given as 2900 g/m²/24 hr and 275g/m²/24 hr is given as 300 g/m²/24 hr).

Sample Preparation

Preparation of Laminates

Glue Sheets are Prepared Ahead of Time on an X-Y Table (i.e., a tableequipped with a mechanical glue head that can travel in both the x and ydirections) by applying adhesive code H2861 available from BostikFindley, Wauatosa, Wis., using a single nozzle head in a spiral patternwith a 5 mm overlap on Silicon coated release paper. Pre-determined cutpieces of a 27 gsm High Elongation Carded nonwoven (NW) available fromBBA Nonwovens, Old Hickory, Tenn., are cut for laminate making. Twopieces of nonwovens are secured properly to a rubber mat by tape whileglue sheets are placed on top of secured nonwovens. While the other sideof glue sheets are still covered with release paper, a roller is used topress/transfer adhesive from the release papers to the nonwoven. Therelease paper is removed from the first nonwoven to expose the adhesive.A predetermined length of elastic film (as disclosed in Examples 1-3below) is placed on top of first nonwoven/adhesive followed by placing asheet of release paper on the film. A roller is used to press the filmagainst the first nonwoven/adhesive. The release paper is removed fromthe film. The release paper on second nonwoven/adhesive is removed. Thesecond nonwoven/adhesive is placed on top of film so the adhesive fromthe second nonwoven is in contact with film. A roller is used to applypressure to bond the second nonwoven to the elastomeric film. Thisprocess results in production of trilaminate containing adhesivelybonded stretch film between two layers of nonwoven. Laminates are cutinto a 75 mm (cross machine direction of the film)×80 mm (machinedirection of the film) rectangle using a ruler and rolling blade.

Activation of Laminates

Elastic laminates are mechanically activated to simulate ring rollingactivation process as described in U.S. Pat. No. 6,843,134. Manualactivation in this instance refers to using aluminum plates withinter-meshing teeth to selectively stretch portions of the laminate suchthat the nonwoven is broken and/or elongated and the elastic film isable to extend and retract without being unduly encumbered by thenonwoven. The laminates are allowed to age for a minimum of 1 day afterfabrication and before activation. The laminates are activated with theelongation imparted in the cross direction (CD) with a target strain of260% and a target strain rate of 533 s⁻¹. The pitch between theactivation teeth is approximately 3.810 mm.

EXAMPLES Example 1

A 34 gsm thermoplastic polyurethane block copolymer cast film availablefrom Deerfield Urethane, Inc., South Deerfield, Mass. as Dureflex X2104(lot #03162005) was laminated, activated and tested according to theabove methods. Dureflex X2104 comprises Estane X-1007 from Noveon, Inc.,Cleveland, Ohio. Estante X-1007 is reported as having Tg's of −61° C.and 140° C.

Example 2

A 55 gsm thermoplastic polyurethane block copolymer cast extruded filmavailable from Noveon, Inc., Cleveland, Ohio, as a 90%/10% admix ofEstane X-1007-031/X-1206 was laminated, activated, and tested accordingto the above methods.

Example 3 Comparative

A 59 gsm thermoplastic coextruded styrenic block copolymer filmavailable from Nordenia USA, Inc., Jackson, Mo., under supplier codeKG6361.000 (lot NOGG53576) was laminated, activated, and testedaccording to the above methods.

Test Data

TABLE 1 Sustained Load Force Relaxation and MVTR Data Force Relaxation %Force Relaxation % MVTR (4 hours) (10 hours) (g/m²/24 hours) Example 140 43 1400 Example 2 39 43 1200 Example 3 46 53 300

As shown above in Table 1, the force relaxation of the polyurethanebased laminates (Examples 1 & 2) are significantly lower than the forcerelaxation of co-extruded styrenic block copolymer laminates.Additionally, a significant improvement in breathability of theselaminates is also demonstrated.

TABLE 2 200% 2-Cycle Hysteresis Data Load @ 200% Unload @ Load @ 200%Load @ 200% Unload @ (Cycle 1) 50% (Cycle 1) to Unload @ (Cycle 2) 50%(Cycle 2) Sample ID (N/cm) (N/cm) 50% (N/cm) (N/cm) Example 1 2.63 0.1715.5 2.19 0.16 Example 2 3.30 0.27 12.2 2.77 0.24 Example 3 1.97 0.277.3 1.75 0.25

As exhibited in Table 2, the hysteresis data shows that at comparablebasis weights (55 gsm for Example 2 and 59 gsm for Example 3), theunload forces are similar for the polyurethane based laminates and thestyrenic block copolymer laminates. However, as the basis weight of thepolyurethane film is reduced (e.g., 34 gsm for Example 1), the unloadforce is likewise diminished compared the styrenic block copolymerlaminate. In general, it is desirable to have high unload forces (e.g.,unload forces that more closely approximate the load forces). However,it is even more desirable that the force be maintained during strain(i.e., a low force relaxation). In this case, lower unload forces areacceptable since the polyurethane laminates exhibit a reduced forcerelaxation as compared to the styrenic block copolymer based laminates.As a result, the lower basis weight polyurethane laminate is expected toexhibit unload comparable to the higher basis weight styrenic blockcopolymer based laminate after 10 hours under strain.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the present invention. To the extent that any definitionor meaning of a term in this written document conflicts with adefinition or meaning of the term in a document incorporated byreference, the definition or meaning assigned to the term in thisdocument shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

1. A process for making a disposable absorbent article comprising thesteps of: a) providing a first nonwoven web; b) joining an elasticmember comprising a first polyurethane to a first region of the firstnonwoven web; c) incrementally stretching at least a portion of thefirst region to permanently elongate the nonwoven web thereby forming astretch laminate, wherein said stretch laminate exhibits a MVTR greaterthan about 300 grams per square meter per 24 hours and a forcerelaxation of less than about 50% after about 10 hours at 100° F. and50% elongation; and d) incorporating said stretch laminate into adisposable absorbent article.
 2. The process of claim 1 wherein the stepof joining the elastic member is performed by printing the firstpolyurethane in a fluid or molten state to the first nonwoven web. 3.The process of claim 2 wherein printing the first polyurethane isperformed by direct gravure printing, offset gravure printing orflexographic printing.
 4. The process of claim 1 wherein the stretchlaminate is incorporated into an elastic element of the disposableabsorbent article; wherein said elastic element is selected from thegroup consisting of, a waist feature, a side panel, an ear, an analcuff, an elastic backsheet, an elasticized topsheet, a fastening system,a leg cuff, and combinations thereof.
 5. The process of claim 1 whereinthe first polyurethane is a phase-separating material having at least afirst phase with a first glass transition temperature of less than −40°C. and a second phase with a second glass transition temperature ofgreater than 100° C.
 6. The process of claim 1 wherein the step ofjoining the elastic member further comprises the substeps of i)providing a cooling drum rotating about an axis and having a cooledouter surface; ii) providing an extruder extruding the firstpolyurethane in a molten or softened form onto the cooled outer surfaceof the cooling drum to form the elastic member; iii) providing first andsecond rollers rotating about parallel axis and forming a niptherebetween, wherein the first roller is positioned proximate to thecooled surface of the drum; iv) conveying a first substrate to thesecond roller; v) conveying the elastic member from the cooled outersurface of the drum to the first roller; and vi) passing the elasticmember and the substrate through the nip to join the elastic members tothe first substrate.
 7. The process of claim 6 wherein the firstpolyurethane is a phase-separating material having at least a firstphase with a first glass transition temperature of less than −40° C. anda second phase with a second glass transition temperature of greaterthan 100° C.
 8. A process for making a disposable absorbent articlecomprising the steps of: a) providing a first nonwoven web; b) joiningan elastic member comprising a first polyurethane to a first region ofthe first nonwoven web while said elastic member is in an elongatedstate; c) allowing the elastic member to recover to form a stretchlaminate, wherein said stretch laminate exhibits a MVTR greater thanabout 300 grams per square meter per 24 hours and a force relaxation ofless than about 50% after about 10 hours at 100° F. and 50% elongation;and d) incorporating said stretch laminate into a disposable absorbentarticle.
 9. The article of claim 8 wherein the elastic member has abasis weight of less than about 100 g/m².